U.S. patent application number 12/571083 was filed with the patent office on 2011-03-31 for substrate and rubber composition and method of making the composition.
This patent application is currently assigned to Federal-Mogul Corporation. Invention is credited to Richard E. Dewald, Suky Singh.
Application Number | 20110076501 12/571083 |
Document ID | / |
Family ID | 43780710 |
Filed Date | 2011-03-31 |
United States Patent
Application |
20110076501 |
Kind Code |
A1 |
Dewald; Richard E. ; et
al. |
March 31, 2011 |
SUBSTRATE AND RUBBER COMPOSITION AND METHOD OF MAKING THE
COMPOSITION
Abstract
This invention provides a product comprised of a substrate with
a rubber composition attached to the substrate by at least one
interlayer of a polysilsesquioxane composition having phosphate
cross-linkages. The at least one polysilsesquioxane layer having
phosphate cross-linkages is produced from a mixture of a silane
coupling agent and a phosphatizing reagent.
Inventors: |
Dewald; Richard E.;
(Clinton, MI) ; Singh; Suky; (Ann Arbor,
MI) |
Assignee: |
Federal-Mogul Corporation
Southfield
MI
|
Family ID: |
43780710 |
Appl. No.: |
12/571083 |
Filed: |
September 30, 2009 |
Current U.S.
Class: |
428/416 ;
156/329; 428/421; 428/425.5; 428/447 |
Current CPC
Class: |
B32B 9/005 20130101;
B32B 2307/30 20130101; Y10T 428/3154 20150401; Y10T 156/1352
20150115; Y10T 156/137 20150115; B32B 2307/712 20130101; B32B 9/043
20130101; B32B 25/14 20130101; C09J 2301/504 20200801; Y10T
428/31598 20150401; B32B 25/08 20130101; B32B 15/18 20130101; B32B
2255/205 20130101; B32B 2255/10 20130101; Y10T 156/1335 20150115;
B32B 25/16 20130101; Y10T 156/1357 20150115; Y10T 156/1343
20150115; B32B 15/08 20130101; B32B 7/12 20130101; Y10T 156/1361
20150115; B32B 2581/00 20130101; Y10T 156/1365 20150115; Y10T
156/1348 20150115; B32B 9/041 20130101; C09J 5/02 20130101; B32B
2255/00 20130101; B32B 15/20 20130101; Y10T 428/31663 20150401;
B32B 15/06 20130101; Y10T 428/31522 20150401; B32B 2307/50
20130101; B32B 2255/06 20130101; Y10T 156/1339 20150115 |
Class at
Publication: |
428/416 ;
156/329; 428/447; 428/421; 428/425.5 |
International
Class: |
B32B 7/12 20060101
B32B007/12; B32B 15/08 20060101 B32B015/08; B32B 37/12 20060101
B32B037/12 |
Claims
1. A method for attaching a rubber composition to a substrate,
comprising: obtaining a mixture of a silane coupling agent and a
phosphatizing reagent; treating a surface of the substrate with the
mixture; and attaching the rubber composition to the treated
surface of the substrate.
2. The method of claim 1, wherein the silane coupling agent is at
least one silane selected from the group consisting of
amino-silanes, mercapto-silanes, expoxy-silanes, carboxy-silanes,
vinyl-silanes, and halogen-containing silanes.
3. The method of claim 2, wherein the mixture further comprises at
least one phenolic resin.
4. The method of claim 1, wherein the silane coupling agent is at
least one silane selected from the group consisting of
amino-silanes and vinyl silanes.
5. The method of claim 4, wherein the mixture is prepared without
adding phenolic resin.
6. The method of claim 1, wherein the phosphatizing reagent is at
least one phosphoric acid compound or phosphonic acid compound.
7. The method of claim 1, wherein the rubber composition is a
diene-series rubber, an olefinic rubber, an acrylic rubber, a
fluorine-containing rubber, a silicone-series rubber, a
urethane-series rubber, an epichlorohydrin rubber, a
chlorosulfonated polyethylene, a propylene oxide rubber, an
ethylene-vinyl acetate copolymer, a polynorbornene rubber, or a
modified rubber thereof.
8. The method of claim 1, wherein the substrate is a metal, a
ceramic compound having a metal surface, or a thermoplastic polymer
having a metal surface.
9. The composition of claim 8, wherein the substrate is a
metal.
10. A composition comprised of a substrate attached to a rubber
composition by at least one polysilsesquioxane layer having
phosphate cross-linkages.
11. The composition of claim 10, wherein the substrate is a metal,
a ceramic compound having a metal surface, or a thermoplastic
polymer having a metal surface.
12. The composition of claim 10, wherein the substrate is a
metal.
13. The composition of claim 10, wherein the rubber composition is
a diene-series rubber, an olefinic rubber, an acrylic rubber, a
fluorine-containing rubber, a silicone-series rubber, a
urethane-series rubber, an epichlorohydrin rubber, a
chlorosulfonated polyethylene, a propylene oxide rubber, an
ethylene-vinyl acetate copolymer, a polynorbornene rubber, or a
modified rubber thereof.
14. The composition of claim 10, wherein the at least one
polysilsesquioxane layer having phosphate cross-linkages is
produced from a mixture of a silane coupling agent and a
phosphatizing reagent.
15. The composition of claim 14, wherein the silane coupling agent
is at least one silane selected from the group consisting of
amino-silanes, mercapto-silanes, expoxy-silanes, carboxy-silanes,
vinyl-silanes, and halogen-containing silanes.
16. The composition of claim 15, wherein the mixture further
comprises at least one phenolic resin.
17. The composition of claim 14, wherein the silane coupling agent
is at least one silane selected from the group consisting of
amino-silanes and vinyl silanes.
18. The composition of claim 17, wherein the mixture is prepared
without adding phenolic resin.
19. The composition of claim 14, wherein the phosphatizing reagent
is at least one phosphoric acid compound or phosphonic acid
compound.
20. The composition of claim 10, wherein the composition is a seal.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a method for attaching a rubber
composition to a substrate. The invention also relates to a product
produced by the method in which the product is comprised of a
substrate attached to a rubber composition by at least one
polysilsesquioxane layer having phosphate cross-linkages.
BACKGROUND OF THE INVENTION
[0002] Products or compositions that are comprised of a substrate
and a rubber composition attached to the substrate are used for any
number of applications. In applications in which there are extreme
environmental conditions such as high temperatures, high pressures,
and high stress situations, the substrate and rubber composition
not only have to stand up to the extreme conditions to avoid
corrosion or erosion, the substrate and rubber composition should
have high reliability in staying attached to one another.
[0003] In particular applications such as seals, the substrate is
generally treated to either aid in environmental resistance to the
substrate, aid in attaching the rubber composition to the substrate
or both. Such treatments have included treatment with zinc
phosphate, iron phosphate, manganese phosphate, or a similar-type
metal composition.
[0004] U.S. Pat. No. 7,354,658 discloses a metal substrate in which
a rubber is adhered to a portion of the substrate surface. In order
to improve the adhesive property between the metal and the rubber,
the surface is roughened. The substrate is then treated using a
zinc phosphate treatment, and a rubber composition is then attached
to produce a seal as a final product.
[0005] U.S. Pat. No. 7,384,028 discloses a rubber part having a
metal fitting in which the metal fitting and the rubber part are
integrated through an anti-corrosion chemical film formed on a
surface of the metal fitting. The anti-corrosion chemical film is a
zirconium-based chemical film that is stated to be harmless to the
human body as well as to the environment. The rubber and metal
fitting is produced by degreasing an outer peripheral surface of
the metal fitting, subjecting the surface to shot blasting
treatment, degreasing the treated surface, and water washing the
treated surface; forming a zirconium-based chemical film on the
treated surface; water washing and drying an outer peripheral
surface of the zirconium-based chemical film; forming an adhesive
layer on the outer peripheral surface of the zirconium-based
chemical film; and integrating the rubber part on the outer
peripheral surface of the adhesive layer.
[0006] Additional methods of producing products comprised of
substrate and rubber components are desired. It is particularly
desired to find new methods to produce products that are better
able to withstand extreme environmental operating conditions. Also
desirable are new methods that reduce or eliminate the use of metal
treatment steps that result in having to dispose of excess metals
used during manufacture. It is further desired to find new methods
that reduce or simplify the steps of the manufacturing process.
SUMMARY OF THE INVENTION
[0007] This invention provides a product comprised of a substrate
and rubber composition attached to the substrate in which the
product and its components are able to withstand extreme
environmental conditions. The product is produced using methods
that significantly reduce or eliminate the use of metal treatment
steps that result in having to dispose of excess metals used during
the process. The processes used to produce the product also reduce
or simplify the steps of previously used manufacturing
processes.
[0008] According to one aspect of the invention, there is provided
a method for attaching a rubber composition to a substrate. The
method includes preparing or obtaining a mixture of a silane
coupling agent and a phosphatizing reagent. A surface of the
substrate is treated with the mixture, and the rubber composition
is attached to the treated surface of the substrate.
[0009] According to another aspect of the invention, there is
provided a product or composition comprised of a substrate attached
to a rubber composition by at least one polysilsesquioxane layer
having phosphate cross-linkages. The at least one
polysilsesquioxane layer having phosphate cross-linkages is
produced from the mixture of a silane coupling agent and a
phosphatizing reagent.
[0010] Preferably, the silane coupling agent is at least one silane
selected from the group consisting of amino-silanes,
mercapto-silanes, expoxy-silanes, carboxy-silanes, vinyl-silanes,
and halogen-containing silanes.
[0011] In one embodiment of the invention, the mixture that is
prepared to apply to the substrate further comprises at least one
phenolic resin.
[0012] In another embodiment, the silane coupling agent is at least
one silane selected from the group consisting of amino-silanes and
vinyl silanes. In this embodiment, it is preferred that the mixture
is prepared without adding phenolic resin.
[0013] In yet another embodiment of the invention, the
phosphatizing reagent is at least one phosphoric acid compound or
phosphonic acid compound.
[0014] In another embodiment, the rubber composition is a
diene-series rubber, an olefinic rubber, an acrylic rubber, a
fluorine-containing rubber, a silicone-series rubber, a
urethane-series rubber, an epichlorohydrin rubber, a
chlorosulfonated polyethylene, a propylene oxide rubber, an
ethylene-vinyl acetate copolymer, a polynorbornene rubber, or a
modified rubber thereof.
[0015] The substrate is preferably a metal, a ceramic compound
having a metal surface, or a thermoplastic polymer having a metal
surface. More preferably, the substrate is a metal.
DETAILED DESCRIPTION OF THE INVENTION
[0016] This invention provides a composition comprised of a
substrate with a rubber composition attached to the substrate by at
least one interlayer of a polysilsesquioxane composition having
phosphate cross-linkages. The composition is extremely durable in
extreme environments such as high temperature, high pressure, and
high stress conditions. The polysilsequioxane layer or composition
can be applied to the substrate using an environmentally friendly
process in that the use of undesirable metal pretreatment steps are
not required in making the composition.
[0017] The polysilsesquioxane composition having phosphate
cross-linkages is produced by applying or treating a mixture of a
silane coupling agent and a phosphatizing reagent to a surface of
the substrate. The mixture itself is produced by mixing together an
amount of the silane coupling agent and phosphatizing reagent
effective for forming a polysilsesquioxane composition having
phosphate cross-linkages to the substrate surface.
[0018] In one embodiment, the mixture is formed by the addition of
from 0.1 wt % to 20 wt % of the silane coupling agent, based on
total weight of the mixture, to a vessel or container that is used
to hold or mix together the components in the mixture. Preferably,
the mixture is formed from the addition of from 0.2 wt % to 15 wt
%, more preferably from 0.5 wt % to 10 wt % of the silane coupling
agent, based on total weight of the mixture.
[0019] The silane coupling agent can be any silane composition
capable of forming polysilsesquioxane. Examples of useful silane
coupling agents include amino-silanes, mercapto-silanes,
expoxy-silanes, carboxy-silanes, vinyl-silanes, and
halogen-containing silanes.
[0020] Examples of amino-silanes include, but are not limited to,
gamma-aminopropyltrimethoxysilane,
gamma-aminopropyltriethoxysilane,
gamma-aminopropylmethyldimethoxysilane,
gamma-aminopropylmethyldiethoxysilane, gamma-(2-aminoethyl)
aminopropyltrimethoxysilane, gamma-(2-aminoethyl)
aminopropylmethyldimethoxysilane, gamma-(2-aminoethyl)
aminopropyltriethoxysilane, gamma-(2-aminoethyl)
aminopropylmethyldiethoxysilane,
.gamma.-ureidepropyltrimethoxysilane,
N-phenyl-gamma-aminopropyltrimethoxysilane,
N-benzyl-gamma-aminopropyltrimethoxysilane and
N-vinylbenzyl-gamma-aminopropyltriethoxysilane.
[0021] Examples of mercapto-silanes include, but are not limited
to, gamma-mercaptopropyltrimethoxysilane,
gamma-mercaptopropyltriethoxysilane,
gamma-mercaptopropylmethyldimethoxysilane and
gamma-mercaptopropylmethyldiethoxysilane.
[0022] Examples of epoxy-silanes include but are not limited to
gamma-glycidoxypropyltrimethoxysilane,
gamma-glycidoxypropyltriethoxysilane,
gamma-glycidoxypropylmethyldimethoxysilane,
beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane and
beta-(3,4-epoxycyclohexyl)ethyltriethoxysilane.
[0023] Examples of carboxy-silanes include, but are not limited to,
beta-carboxyethyltriethoxysilane,
beta-carboxyethylphenylbis(2-methoxyethoxy)silane and
N-beta-(carboxymethyl)aminoethyl-gamma-aminopropyltrimethoxysilane.
[0024] Examples of vinyl-silanes include, but are not limited to,
vinyltrimethoxysilane, vinyltriethoxysilane,
gamma-methacryloyloxypropylmethyldimethoxysilane and
gamma-acryloyloxypropylmethyltriethoxysilane.
[0025] An example of a halogen-containing silane includes, but is
not limited to, gamma-chloropropyltrimethoxysilane.
[0026] In one embodiment of the invention, the mixture is formed
from the addition of from 1 wt % to 20 wt % of the phosphatizing
reagent, based on total weight of the mixture. Preferably, the
mixture is formed from the addition of from 2 wt % to 15 wt %, more
preferably from 3 wt % to 10 wt % of the phosphatizing reagent,
based on total weight of the mixture.
[0027] The phosphatizing reagent can be any phosphorus-containing
acid that is effective for crosslinking with polysilsesquioxane.
Any suitable phosphoric acid compound or phosphonic acid compound
is preferred.
[0028] Preferred phosphoric acid compounds include phosphoric acid
compounds of the general formula:
##STR00001##
[0029] wherein R and R', which can be the same or different, are H,
alkyl of 1 to 30 carbons and aryl of 6 to 30 carbons, n is an
integer of from 1 to 6; including +1 and +2 metal salts of the
phosphoric acid compounds.
[0030] Examples of phosphoric acids and their salts include, but
are not limited to, phosphoric acid (mono-alkyl and di-alkyl
phosphoric acid, with alkyl having 1 to 10 carbons), mono-n-dodecyl
phosphate, tridecyl acid phosphate, oleyl acid phosphate, octadecyl
acid phosphate, di-n-amyl phosphate, distearyl phosphate,
n-butyldihydrogen phosphate, calcium dihydrogen phosphate, aluminum
dihydrogen phosphate, D-myo-inositol 1,4-biphosphate, potassium
salt, (R,S)-(+,-)-1,1'-binaphthyl-2,2'-diylhydrogenphosphate,
D-myo-inositol triphosphate, potassium salt, D-myo-inositol,
1,3,4,5-tetraphosphate, D-myo-inositol pentaphosphate, barium salt,
inositol hexaphosphoric acid (phytic acid), sodium phytate, phenyl
phosphoric acid, and di-phenyl phosphoric acid.
[0031] Preferred phosphonic acid compounds include phosphonic acid
compounds of the general formula:
##STR00002##
[0032] wherein R is alkyl of 1 to 30 carbons and aryl of 6 to 30
carbons, n is an integer of from 1 to 6; including +1 and +2 metal
salts of the phosphonic acids.
[0033] Examples of phosphonic acids and their salts include, but
are not limited to, phosphonic acid (mono-alkyl and di-alkyl
phosphonic acid, with alkyl having 1 to 10 carbons),
n-dodecylphosphonic acid, ethylphosphonic acid, phenyl phosphonic
acid, di-phenyl phosphonic acid, n-hexylphosphonic acid,
n-butylphosphonic acid, n-decylphosphonic acid, n-undecylphosphonic
acid, n-tridecylphosphonic acid, n-tetradecylphosphonic acid,
n-pentadecylphosphonic acid, propylene diphosphonic acid,
N,N-bis(phosphonomethyl)glycine, 1,2-ethylenediphosphonic acid,
methylenediphosphonic acid, 1,1-ethylidenediphosphonic acid,
dimethylmethylenediphosphonic acid,
nitrilotris(methylene)triphosphonic acid,
ethylenediaminetetra(methylenetriphosphonic acid),
hexamethylenediaminetetra(methylenetriphosphonic acid),
diethylenetriaminepenta(methylenetriphosphonic acid),
inositolhexaphosphonic acid, and calcium, magnesium
inositolhexaphosphate salt.
[0034] In one embodiment of the invention, the mixture of
phosphatizing reagent and silane coupling agent further comprises
the addition of at least one phenolic resin. The phenolic resin can
be a resol resin, a novolac resin, or a combination thereof.
[0035] In one embodiment, the mixture is formed from the addition
of from 1 wt % to 40 wt % phenolic resin, based on total weight of
the mixture. Preferably, is formed from the addition of from 5 wt %
to 40 wt %, more preferably from 20 wt % to 40 wt %, of the
phenolic resin, based on total weight of the mixture.
[0036] In general, resol resins are produced by reacting a phenol
compound with a stoichiometric excess of an aldehyde compound in
the presence of an alkaline catalyst. Novolac resins are generally
produced by reacting an aldehyde compound with a stoichiometric
excess of a phenol compound in the presence of an acid
catalyst.
[0037] Phenol compounds used in the production of the phenolic
resins used in this invention include, but are not limited to,
monophenols (e.g. phenol, trimethylphenol, ethylphenol,
m-propylphenol, butylphenol, m-sec-butylphenol, m-isobutylphenol,
m-tert-butylphenol, m-bromophenol, m-chlorophenol, m-phenylphenol,
m-benzylphenol, octylphenol, m-cetylphenol, m-cumylphenol,
m-hydroxyacetophenol, m-hydroxybenzophenone, m-d-limonenephenol,
o-cresol, m-cresol, p-cresol, 2,3-xylenol, 2,4-xylenol,
2,5-xylenol, 2,6-xylenol, 3,4-xylenol, 3,5-xylenol, etc.) and
biphenols (e.g. catechol, resorcinol, hydroquinone, bisphenol A,
etc.).
[0038] Aldehyde compounds used in the production of the phenolic
resins used in this invention include, but are not limited to,
formaldehyde and modified forms thereof, e.g., not less than 37%
formalin, paraldehyde, acetaldehyde, propionaldehyde and
isobutylaldehyde, and isopentylaldehyde. Formaldehyde is a
preferred example. Formaldehyde can be used as an aqueous solution
(not less than 37 weight %) or in the form of a low molecular
weight polymer such as paraformaldehyde or trioxane. Other
non-limiting examples of the aldehyde include furfural,
2-ethylhexanal, ethylbutylaldehyde, heptaldehyde, benzaldehyde and
crotonaldehyde.
[0039] In a particular embodiment of the invention, the mixture is
formed from at least one phosphatizing reagent and at least one
silane coupling agent selected from the group consisting of
amino-silanes and vinyl-silanes. Preferably, in one embodiment, the
mixture is formed from at least one phosphatizing reagent and at
least one silane coupling agent selected from the group consisting
of amino-silanes and vinyl-silanes, without adding phenolic resin
to produce the mixture.
[0040] Substrates that can be used according to this invention
include any appropriate substrate in which the substrate can be
treated with the mixture used in this invention and to which a
rubber composition can then be attached. A metal, a ceramic
compound, or a thermoplastic polymer can be used as the substrate.
In one embodiment, the substrate is a metal, a ceramic compound
having a metal surface, or a thermoplastic polymer having a metal
surface. Examples of metals that can be used in this invention
include, but are not limited to, carbon steel, stainless steel,
aluminum, aluminum alloy, titanium, titanium alloy, magnesium,
magnesium alloy, and metal coated with one or more different
metallic or organic layers.
[0041] According to one aspect of the invention, the substrate is
treated with the mixture of this invention. In one embodiment, the
substrate is treated with the mixture at a temperature of not
greater than 150.degree. F. (66.degree. C.). Preferably, the
substrate is treated with the mixture at a temperature of from
40.degree. F. (4.degree. C.) to 150.degree. F. (66.degree. C.),
more preferably from 50.degree. F. (4.degree. C.) to 120.degree. F.
(49.degree. C.), and most preferably from 60.degree. F. (16.degree.
C.) to 100.degree. F. (38.degree. C.).
[0042] Following treatment of the substrate, the treated substrate
is dried. Preferably, the substrate is dried at a temperature of
from 158.degree. F. (70.degree. C.) to 248.degree. F. (120.degree.
C.), more preferably from 176.degree. F. (80.degree. C.) to
230.degree. F. (110.degree. C.), and most preferably from
194.degree. F. (90.degree. C.) to 221.degree. F. (105.degree.
C.)
[0043] The rubber composition that is attached to the treated
substrate used in this invention can be cured or uncured, wherein
cured rubber is preferred. Examples of curing processes include,
but are not limited to, soap, sulfur (e.g., vulcanization),
diamine, onium salts, peroxide and bisphenol.
[0044] Examples of types of rubber that can be used according to
this invention include, but are not limited to, a diene-series
rubber, an olefinic rubber, an acrylic rubber, a
fluorine-containing rubber, a silicone-series rubber (e.g., a
silicone rubber), a urethane-series rubber, an epichlorohydrin
rubber (e.g., a homopolymer of epichlorohydrin (CO), a copolymer of
epichlorohydrin and ethylene oxide (ECO), and a copolymer further
copolymerized with allyl glycidyl ether), a chlorosulfonated
polyethylene, a propylene oxide rubber (GPO), an ethylene-vinyl
acetate copolymer (EAM), a polynorbornene rubber, and a modified
rubber thereof (e.g., an acid-introduced (or acid-modified)
rubber). These rubbers may be used singly or in combination.
[0045] Examples of diene-series rubber include, but are not limited
to, natural rubber (NR); polymers of diene-series monomers, such as
an isoprene rubber (IR), isobutylene-isoprene rubber (butyl rubber)
(IIR), butadiene rubber (BR), chloroprene rubber (CR);
acrylonitrile-diene copolymerized rubber such as an
acrylonitrile-butadiene rubber (nitrile rubber) (NBR),
nitrile-chloroprene rubber (NCR), nitrile-isoprene rubber (NIR), or
acrylonitrile-isoprene-butadiene rubber (NBIR); styrene-diene
copolymerized rubber such as a styrene-butadiene rubber (SBR, for
example, random copolymers of styrene and butadiene, a SB-block
copolymer comprised of styrene blocks and butadiene blocks),
styrene-chloroprene rubber (SCR), and styrene-isoprene rubber
(SIR).
[0046] Diene-series rubber can further include hydrogenated rubber,
for example, hydrogenated nitrile rubber (HNBR). A proportion of a
styrenic component in styrene-diene copolymerized rubbers can be
from about 10 to 80 mol %, preferably about 20 to 70 mol % and more
preferably about 30 to 60 mol % in terms of the monomers making up
the copolymer.
[0047] Examples of olefinic rubber include, but are not limited to,
ethylene-propylene rubber (EPM), and ethylene-propylene-diene
rubber (EPDM).
[0048] Examples of acrylic rubber include rubber comprised of alkyl
acrylate as a main component, such as a copolymer of an alkyl
acrylate and a chlorine-containing crosslinkable monomer (ACM), a
copolymer of an alkyl acrylate and acrylonitrile (ANM), a copolymer
of an alkyl acrylate and a carboxyl group- and/or epoxy
group-containing monomer, and an ethylene-acrylic rubber.
[0049] Examples of fluorine-containing rubber include, but are not
limited to, rubber obtained by using a fluorine-containing monomer,
for example, a copolymer of vinylidene fluoride and
perfluoropropene, and optionally, tetrafluoroethylene (FKM); a
copolymer of tetrafluoroethylene and propylene; a copolymer of
tetrafluoroethylene and perfluoromethyl vinyl ether (FFKM).
[0050] Silicone-series rubber (Q) refers to an organopolysiloxane
comprising units represented by the formula R.sub.aSiO.sub.(4-a)/2
wherein R represents C.sub.1-10 alkyl such as methyl, ethyl, propyl
or butyl; halogenated C.sub.1-10 alkyl such as 3-chloropropyl or
3,3,3-trifluoropropyl group; C.sub.2-10 alkenyl such as vinyl,
allyl or butenyl; C.sub.6-12 aryl such as phenyl, tolyl or
naphthyl; C.sub.3-10 cycloalkyl such as cyclopentyl or cyclohexyl;
C.sub.6-12 aryl-C.sub.1-4 alkyl such as benzyl or phenethyl, and
"a" is from about 1.9 to about 2.1. Preferably, R is methyl,
phenyl, alkenyl (e.g., vinyl group), or fluoro C.sub.1-6 alkyl.
[0051] The silicone-series rubber (Q) includes, for example, a
methylsilicone rubber (MQ), a vinylsilicone rubber (VMQ), a
phenylsilicone rubber (PMQ), a phenylvinylsilicone rubber (PVMQ), a
fluorosilicone rubber (FVMQ), and the like. Further, such a
silicone-series rubber includes not only a solid rubber of the High
Temperature Vulcanizable (HTV) silicone rubber but also a Room
Temperature Vulcanizable (RTV) silicone rubber or Low Temperature
Vulcanizable (LTV) silicone rubber, for example a liquid or
paste-like rubber.
[0052] Examples of urethane rubber (U) include, but are not limited
to polyester-based urethane elastomers, and polyether-based
urethane elastomers.
[0053] Modified rubbers can also be used. Examples include, but are
not limited to, acid-modified rubbers such as carboxyl- or acid
anhydride-containing rubber, e.g., a carboxylic styrene-butadiene
rubber (X-SBR), a carboxylic nitrile rubber (X-NBR), and a
carboxylic ethylene-propylene rubber (X-EP(D)M).
[0054] Any method or technique suitable for attaching the rubber
composition to the treated substrate can be used. Examples of
suitable attachment methods include, but are not limited to,
molding, compression molding, injection-transfer molding, transfer
molding, as well as any molding process that allows the substrate
to be held in place in the mold during the molding process,
allowing the substrate to be overmolded. More specific examples of
suitable molding methods or techniques are described in Baranwal,
K. C. and Stephens, H. L., ed., Basic Elastomer Technology, The
Rubber Division, American Chemical Society, Akron, 2001, pp.
132-141, the attachment techniques of which are incorporated herein
by reference.
[0055] The substrate and attached rubber composition produced
according to this invention can be used in any number of ways. In a
preferred embodiment, the product is used as a seal. Preferably,
the product is a radial or radial shaft seal. Radial shaft seals
are used to seal rotary elements, such as a shaft or rotating bore.
Examples include, but are not limited to, crankshaft seals,
transmission output seals, strut seals, hydraulic pump seals, axle
seals, power steering seals, and valve stem seals.
[0056] The principles and modes of operation of this invention have
been described above with reference to various exemplary and
preferred embodiments. As understood by those of skill in the art,
the overall invention, as defined by the claims, encompasses other
preferred embodiments not specifically enumerated herein.
* * * * *